USS Essex Demonstrates Onboard 3D Printing for Parts at Sea

During the multinational RIMPAC 2026 exercise, the Wasp-class amphibious assault ship USS Essex (LHD 2) is showcasing the capability of producing parts at sea using onboard 3D printers. This initiative, part of the Fleet Experimentation Program (FLEX), aims to provide the crew with both additive and subtractive manufacturing tools to overcome logistical challenges.

This onboard manufacturing capability allows the USS Essex crew to create replacement parts for ship systems, Marine Corps equipment, and aviation components, eliminating the need to wait for external supply chains. Gunnery Sgt. Samuel Margarini of Combat Logistics Battalion 13 highlighted that this allows them to "solve problems without waiting on the supply chain."

The process involves receiving a worn part or specifications, creating a digital design, and often printing a plastic prototype to verify dimensions and fit before producing the final piece. For complex components, 3D scanners are used to capture precise measurements for digital recreation. This iterative approach with prototypes helps to confirm exact measurements, reduce waste, and save time.

Cmdr. Jason Pirrallo, the supply officer aboard the Essex, noted that this on-demand manufacturing significantly reduces administrative hurdles and the time from requesting a part to receiving it, as the entire process occurs on the ship. This is particularly crucial for parts that are no longer manufactured or have become obsolete, supplementing the traditional supply system and ensuring equipment remains operational.

The ship’s medical department also stands to benefit, with the potential to print and sterilize medical equipment components for patient care. This demonstration aligns with a broader U.S. Navy strategy to integrate additive manufacturing as a warfighting capability, enhancing self-sufficiency and mitigating vulnerabilities in supply chains, especially in contested maritime environments.